1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 8 2016 04 11 Revised See Summary of Revisions A. Reaume, NA 2016 02 29 Revised See Summary of Revisions A. Reaume, NA 2008 03 20 Activated Marcos Rogrio de Souza Controlled document at www.MATS Copyright 2016, Ford Global Technologies, L
2、LC Page 1 of 20 COOLANT, ORGANIC ADDITIVE TECHNOLOGY (OAT), WSS-M97B44-D CONCENTRATE, FOR PASSENGER CAR AND LIGHT TRUCK 1. SCOPE The material defined by this specification is a coolant concentrate composed essentially of virgin monoethylene glycol and OAT corrosion inhibitors. When mixed 50/50 with
3、water it shall be a satisfactory fluid for vehicle cooling systems that contain aluminum engine components, radiators and heater cores, ferrous metals and copper brass. This material is for initial fill and service fill. 2. APPLICATION This specification was released originally for passenger car and
4、 light truck and commercial truck applications without the use of nitrites. It should not be mixed with previously approved coolants including silicated coolants per WSS-M97B51-A1. This material is not suitable for use with magnesium based alloys or zinc coatings (e.g. galvanized product). 3. REQUIR
5、EMENTS 3.1 APPROVED SOURCES This specification requires the use of approved sources. Only the sources identified on the Ford Approved Source List (ASL) can be used when this specification is listed on the drawing, CAD file, or other documents. The list of approved sources is located within Ford at
6、or available externally through a Ford Materials Engineer. 3.2 DOCUMENTATION 3.2.1 Approval of a new formulation Supplier must provide a completed and certified copy of the attached Supplement A and test reports demonstrating full compliance with all the requirements of this specification. Suppliers
7、 must provide full disclosure of their material formulation to, and be approved by, Materials Engineering. This disclosure is to a list of each additive by name, target wt%, min and max wt% with sub-supplier names for all components, in particular organic acid technology additives, azoles and other
8、corrosion additives, and ethylene glycol. Disclosure to also include production range levels for pH, reserve alkalinity and water content. All tests must be certified by a qualified and authorized representative of the test facility. Supplier must furnish DFMEA, PFMEA, Process Flow Diagram, and Cont
9、rol Plan. Final approval must be obtained from the Coolant Subject Matter Expert within Global Core Powertrain Cooling Engineering. A formulation/supplier/blending site cannot be added to the approved source list without this Coolant SME approval. 3.2.2 Approval of a new supplier to an approved form
10、ulation Same as 3.2.1 with surrogate test data where approved by Ford and testing and documentation, at minimum, in the attached PVP compare current coolant with proposed coolant Coupon metal weight change Current Coolant Current Coolant/ Cleaner Proposed Coolant Proposed Coolant/ Cleaner Cleaner Co
11、ntrol ASTM Corrosive Water Al Iron Steel Brass Solder Copper - A negative result indicates a weight gain 3.4.17 Storage Stability Hard water and temperature Supplier must report water quality conditions that may adversely affect the quality of the coolant (inhibitor depletion, lowered life, etc). Th
12、e coolant concentrate form, quality and chemical composition shall not be adversely affected, changed or impacted by storage up to 5 years under environmental conditions of normal distribution and storage. In-vehicle, the coolant mixed with water shall be stable so as not to change in form, quality
13、or composition to adversely affects heat transfer or corrosion inhibition. Hard water solution - Prepare hard water by adding 275mg of calcium chloride (CaCl2) to 1 liter synthetic corrosive water described in the test solution section of ASTM D1384. Prepare six 100 ml coolant samples using the test
14、 coolant and the hard water solution. Samples are to have coolant concentrations of 100% (samples 1 and 2), 75% (samples 3 and 4) and 50% (samples 5 and 6). Put all samples in clean, labeled polymethylpentene (PMP) bottles for testing. (French square-type bottle may aid visual check.) All samples mu
15、st pass hot and cold storage stability testing for the coolant to pass. ENGINEERING MATERIAL SPECIFICATION WSS-M97B44-D Copyright 2016, Ford Global Technologies, LLC Page 5 of 20 3.4.17.1 Hot Storage Stability - Samples 1, 3 and 5 are heat storage tested in a circulating air oven at 65 +/- 2 C for 1
16、4 days. Remove a 20 ml sample on days 2, 4, 7, 10 and 14. Allow to cool to room temperature. Check for precipitates, deposits, gelation and phase separation. “Fish eyes” on the top (from defoamer) is acceptable. If anything other than “fish eyes” is present, such as gel or material in solution or pr
17、ecipitate, terminate test and write as failure. Analyze coolant to determine effect. 3.4.17.2 Cold Storage Stability - Samples 2, 4 and 6 are cold storage tested at -40C for 14 days. Remove a 20 ml sample on days 2, 4, 7, 10 and 14. Allow to go to room temperature. Check for precipitates, deposits,
18、gelation and phase separation. “Fish eyes” on the top (from defoamer) is acceptable. If anything other than “fish eyes” is present, such as gel or material in solution or precipitate, terminate test and consider as a failure. Analyze coolant to determine effect. 3.4.18 Compatibility with Engine Hot
19、Test Fluids (See compatibility method in WSS-M97B56-A1) Any changes, other than “fish eyes” deem the hot test fluid incompatible with the coolant. 3.4.19 Compatibility with Coolant Seals 10% RSF (Test per WSS-M9P12-A2, para 3.2.2) Initial qualification is completed as part of DV testing, ongoing tes
20、ting for new programs is the responsibility of the seal suppliers. 3.4.20 Compatibility with Thermoplastic Materials (FLTM BO 130-01, 1000 h at 125 +/- 2 C) (Materials identified by program; contact Materials Engineering or PTI Core for a list.) 50/50 % coolant/water, 10 test specimens minimum, Unag
21、ed property values shall be determined at the time of the aged properties determination. Test plastics used in continuous contact with coolant). Test new coolant with approved coolant for comparison. 3.4.20.1 Tensile Strength at Max Load, Report (ISO 527, 5mm/minute test speed) 3.4.20.2 Impact Stren
22、gth, Charpy, Report (ISO 179, Test specimens to be notched before immersion, 23 +/- 2 C) 3.4.21 Compatibility with Heater Hose Material 3.4.21.1 Burst Pressure after Wet Heat Aging (ASTM D380, fill hose with 50/50 coolant and deionized water. Heat to 104 +/- 2C for 2000 hours) WSE-M96D34-A1 -A2 -A3
23、WSS-M96D34-A4/A5 % Change -28 -10 -45 -28 All hose diameters ENGINEERING MATERIAL SPECIFICATION WSS-M97B44-D Copyright 2016, Ford Global Technologies, LLC Page 6 of 20 3.4.21.2 EPDM Hose Extraction Test (Zinc/ Zinc Compound Extraction) Sulfur cured EPDM compounds employ zinc oxide and fatty acids su
24、ch as stearates in their formulations as cure activators. These activators can produce zinc stearate, which can be extracted by engine coolant and re-deposit elsewhere in the system. Excess amounts of this compound can potentially block coolant passages and cause overheat. The following procedure pr
25、ovides a method to evaluate the potential amount of zinc stearate deposits they may see throughout the cooling system based on a standard sample size. Equipment and Materials Three 356 mm X 38.1 hose samples Six 25 mm long plugs of ample outer diameter to seal hose, both ends Six worm gear clamps of
26、 sufficient size for the hose sample One Buchner funnel, 114 mm top diameter and 95 mm perforated diameter Three filter papers for Buchner funnel One 500 ml filter flask with molded rubber stopper Three watch glasses approximately 120 mm diameter One electronic balance capable of weights of 0.001 gr
27、ams Distilled water in squeeze bottle 70% isopropyl alcohol Approximately 320 ml of 45% / 55% coolant / distilled water mixture Convection oven capable of 100C Procedure 1. Rinse the inside of the hose thoroughly with isopropyl alcohol followed by 2 rinses with distilled water to remove any surface
28、contaminants. 2. Plug 1 end of the hose and apply clamp to seal. Fill hose 305 mm deep full of coolant / water mixture. Plug and clamp the open end. Verify no leakage. Bake at 100C for 24 hours. 3. Prior to removal of the hoses from the oven, dry out the filter paper at 100C for 1 hour, or to consta
29、nt weight. Record the filter paper weight. 4. Place the filter paper inside the filter funnel, and apply distilled water to seal the paper to the funnel. 5. Remove a plug from one end of a hose sample and carefully drain the contents onto the filter paper / vacuum filter set up. Pour a small amount
30、of distilled water into the hose, swirl water, drain and repeat the rinse. In any visual residue remains in the hose, repeat rinse as necessary. 6. Using distilled water in a squeeze bottle, wash any solid residue away from the sides of the funnel to the filter paper surface. 7. Tare the watch glass
31、. Carefully remove the filter paper, place on watch glass, and if necessary, use a spatula to collect any additional residue from the funnel sides and add to the filter paper. Bake filter paper at 100C for 24 hours, the compare the pre-test weight and the post-test weight of the filter paper. Accept
32、ance criteria Weight of extractables on the filter paper must weigh less than 1.0 g. ENGINEERING MATERIAL SPECIFICATION WSS-M97B44-D Copyright 2016, Ford Global Technologies, LLC Page 7 of 20 3.4.22 Compatibility with Heater Hose Material and Degas Bottle Material (FLTM BP 108-09, 1000 h at 125 +/-
33、2 C, 50/50 % coolant/ de-ionized or distilled water, Delta E 21 max 3.5 DURABILITY TESTING Note: All failures are to be evaluated via the Global 8D problem solving process. 3.5.1 Dye Stability Test Test Method Make a mixture of 50/50 coolant and deionized water and record pH. Fill an internally flux
34、ed heat exchanger with coolant mixture. Place heat exchanger in oven for 2 weeks at 90C or store at ambient for 60 days. Evaluate the color after test and determine pH. Report change or loss in color. Report pH change. 3.5.2 Aluminum Water Pump Cavitation (ASTM D2809, 3 sample minimum) 3.5.2.1 100 h
35、ours 8 min 3.5.2.2 300 hours 8 min 3.5.3 Simulated Service Corrosion Test (ASTM D2570) Cast iron, steel, brass and copper 10 mg, max Cast aluminum, low lead solder 20 mg, max High lead solder Report Aluminum radiator rating per Appendix I, (Page 20) Tube pitting 5, min Crevice corrosion 5, min Crevi
36、ce corrosion 5, min 3.5.4 Engine Dynamometer Test (FLTM BL 102-02) 3.5.4.1 Radiator Heat Rejection Test, min (QCBTU Method) 85 % of original 3.5.4.2 Heater Core Deposit Weight 1.0 mg/cm2 max 3.5.4.3 Water Pump Evaluation Rating #9 min (Rate per ASTM D2809) 3.5.4.4 Test Coupon Weight Loss At the end
37、of the test, the average weight loss of the 7 similar metal coupons shall not exceed 10 mg/coupon. The weight loss of any individual coupon in the 7 bundles shall not exceed 30 mg. ENGINEERING MATERIAL SPECIFICATION WSS-M97B44-D Copyright 2016, Ford Global Technologies, LLC Page 8 of 20 Determine an
38、d report the weight loss for each coupon that was in for the duration of the test. Determine the sum of all coupons of each type that were tested for 96 h. The sum of the 96 h shall compare favorably (25 % variation) to the duration sums. 3.5.5 Engine Coolant Corrosion Protection Under Accelerated T
39、hermal and Oxidizing Conditions Using a Rotating Pressure Vessel (ASTM D7820, test conditions are 150C +/- 2C in air run in triplicate) For cleaning, use Simple Green Use Viton o-rings (no silicone) Photograph coolant after test Photograph each specimen wiped dry immediately after test (before clean
40、ing) Photograph each specimen immediately after cleaning Report coolant physical and chemical properties before and after the test (pH before, pH after, delta pH, % water before, % water after and delta % water) Report the corrosion weight changes of each individual specimen to the nearest 1 mg (cop
41、per, ASTM solder, brass, steel, cast iron and aluminum) Report each individual corrosion inhibitor level (% remaining is acceptable) Report corrosion metals in solution, individually (aluminum, copper, iron, zinc) Report glycol oxidation/degradation products (glycolate, formate, acetate and total) N
42、ote: If coolant loses 4% or more water during test, it is to be considered suspect test and voided (possible loss of pressure) 3.5.6 FVV Dynamic High Temperature Simulated Service Test Or Other High Temperature Simulated Service Test Method (Note: High temperature service test methods vary depending
43、 on coolant supplier. Test method must be reviewed by and agreed upon with PTI Core Engineering prior to testing.) Acceptance Criteria for FVV: Weight loss in cavitation chamber 40% coolant 30 mg/coupon, max 20% coolant 50 mg/coupon, max Weight loss in coupon 40% coolant 15 mg/coupon, max 20% coolan
44、t 25 mg/coupon, max Overall coolant rating 90/100, minimum All ratings except corrosion Max rating achieved Corrosion rating 30/40, minimum 3.5.7 Stagnant Coolant Solubility and Corrosion Testing (ASTM D7933 and FLTM BL 106-01, Heat exchanger chosen by PTI Core Engineering and Climate Control Engine
45、ering) 3.5.7.1 ASTM D4340 after stagnant and solubility testing. 1 mg/cm2/wk, max Compare result from 3.4.10 for unused coolant. Note: 0.25 0.49 mg/cm2/wk is considered marginal. 0.20 to 0.24 mg/cm2/wk is favorable. less than 0.19 mg/cm2/wk is excellent. ENGINEERING MATERIAL SPECIFICATION WSS-M97B44
46、-D Copyright 2016, Ford Global Technologies, LLC Page 9 of 20 3.5.7.2 Coolant Analysis before and after ASTM D4340 No adverse effect on (ASTM D1123, D1287, D5827, D6130) coolant inhibitors or pH or metals in solution 3.5.7.3 Heat Exchanger after stagnation No deposits or precipitates inside heat exc
47、hanger as a result of the stagnation test 3.5.8 Radiator Internal Corrosion Test (Modified ASTM D2570, Heat exchangers chosen by PTI core engineering Test method to be provided by PTI Cooling PD, Radiator Engineering Specification ES C1BY-8005-AA or latest by program) 3.5.8.1 Internal Corrosion Dama
48、ge Two radiators are to be tested and analyzed post-test. Cut apart core and examine susceptible areas with a microscope for evidence of crevice attack, pitting attack and erosion-corrosion. A minimum of 6 tubes and both headers must be examined. Corrosion pits, crevices, etc. depths are to be estab
49、lished with metallographic cross-sections. If there are no apparent sites of corrosion attack or corrosion build-up, six(6) random tubes sections and one(1) header section from both headers is to be metallurgically examined. No corrosion site on the core tubes or headers shall exceed 10% of the material thickness. 3.5.8.2 Provide 250 ml coolant samples from pre-test, 5 min into test, and post test. Coolant samples are to be analy
